Flat-Folding Box Covers and Methods of Assembly and Methods of Customizing Images on the Box Cover

ABSTRACT

Variations for flat-folding box covers with four distinct design configurations: one piece; two piece; flat-folding structural frames and clear, rigid box covers with decorative inserts. Construction techniques comprise a variety of methods including use of cutout stock sheet materials; use of stiffening panels; use of structural frame elements; use of lamination; use of clear plastic panels; and the use of coatings. Fastening techniques comprise a variety of methods including; magnets, snaps, structural frames, hinges, and adhesives. The end user may purchase finished box covers or components or select from a set of design options offered by a manufacturer; or supply custom decorative images to a manufacturer to apply to the box cover; or purchase a kit in order to make or embellish a box cover themselves. Some designs allow for the end user to update and reconfigure the design elements of the box cover after it is purchased.

This application claims priority from Provisional Patent No. 62/342,352 filed May 27, 2016

RELATED PATENT APPLICATION

Ser. No. 15/083,326, Date filed 2016 Mar. 29

BACKGROUND Most Prior Art Pertinent Patents

Number Patent Holder Date U.S. Pat. No. 3,918,631 A Robert Hackenberg 1971 Jul. 6 U.S. Pat. No. 3,591,071 A Charles W. Rosenberg 1971 Jul. 6 U.S. Pat. No. 3,979,019 A Robert A. Bliss 1976 Sep. 7 U.S. Pat. No. 3,064,876 A R. E. Warner 1962 Nov. 20 U.S. Pat. No. 5,258,247 A Scott J. W. Platzer 1993 Nov. 2 U.S. Pat. No. 7,665,628 B1 Loren Milligan 2010 Feb. 23 US D390391 Junior Julian Hau 1998 Feb. 10 US D494859 Gerald J. Keberlein 2004 Aug. 24 US D514928 Gerald J. Keberlein 2006 Feb. 14

Most Pertinent Prior Art Patent Applications

US 2002/0067038 A1 Lam H/Tran 2002 Jun. 1

Field of the Invention

The present invention relates generally to flat-folding box covers, with specific emphasis on tissue box covers.

Background of the Invention Field

Facial tissues are typically purchased in light cardboard boxes of standard sizes which serve as both the package and the dispenser. These standard tissue boxes may be plain or have decorative designs. They may display the brand name of the manufacturer. The boxes are designed for limited use and are disposed of once all the tissues they contain are gone.

Decorative tissue box covers are designed to be placed over standard tissue boxes in order to conceal the utilitarian nature of the tissue boxes and to provide a more attractive appearance. Versions are available to fit over the standard tissue box size formats which are mainly rectangular or cubical. These decorative tissue box covers have several drawbacks in that they are rigid, they do not fold and they are often heavy. They cannot be readily customized, and their bulk makes them expensive to ship. Box covers that don't fold and are rigid are evidenced in design Pat. Nos. D390391, D494859 and D514928.

The present inventors saw three specific issues they wanted to address in decorative tissue box covers. First, the need for a lightweight, reusable box cover that could be shipped and stored in a flat state; then assembled into a box shape for use; second, the need for a durable, reusable box cover that would not be damaged when assembled and disassembled so it would have a long life and third, a design that would allow users to customize the box cover with their own designs.

Discussion of Prior Art

There are many patents related to tissue boxes and tissue box covers, many deal with disposing of waste tissues, or raising the floor of the box up as tissues are dispensed. Listed next is a description of each patent.

U.S. Pat. No. 3,918,631. This is a flat-folding box which is on a sheet with flaps that are inserted into each other. The top lifts up rather than having an open aperture.

U.S. Pat. No. 3,591,071. This is a carton with several tuck-in flaps. The top lifts up rather than having an open aperture.

U.S. Pat. No. 3,979,019. This is a carton for use in dispensing tissues having a specialized closure. It has several tuck-in flaps that fold over the opening but also have flaps that hold the box together.

U.S. Pat. No. 3,064,876. This package is for gift boxes but it discusses the use of custom decorations. It has tuck-in flaps and a cover.

U.S. Pat. No. 5,258,247. The patent relates to a concept of transparent covering over a box for strength and stability. This cover is sealed to the object.

U.S. Pat. No. 7,665,628. This is a rigid two piece tissue dispenser with a top and a base. The base has a mechanism for lifting up as tissues are dispensed.

US 2002/0067038 A1. This is a rigid box. It has bubble enclosures for holding ornamental pictures.

SUMMARY OF THE INVENTION

This provisional application is for a variety of embodiments of a flat-folding box cover and method of assembly.

The purpose of this invention is to provide a flat-folding box cover as a replacement for a rigid box cover that 1) has a long life due to its rugged construction; 2) has strong decorative appeal and 3) can be customized with end user selected images.

There are four basic starting design variations, all of which have many potential design options:

1) One piece designs

2) Two piece designs

3) Flat-folding structural frame designs

4) Clear, rigid box cover with decorative insert

DESCRIPTIONS OF FIGURES

FIG. 1. Assembled flat-folding box cover with four side panels and a top panel with aperture.

FIG. 2. Flat-folding box cover form with four side panels and a top panel with aperture. The form may have decorative images, embellishments, coatings or lamination.

FIG. 3. Flat-folding box clear plastic box cover showing where the outer limits of each side and to panel.

FIG. 4. Flat-folding box cover form with four side panels and a top panel with aperture and flaps on one edge of the side panels for fastening the box cover together.

FIG. 5. Flat-folding box cover form with four side panels and a top panel with aperture and flaps on both edges of the side panels for fastening the box cover together.

FIG. 6. Flat-folding box cover form with four side panels and a top panel with aperture with bendable hinges between the top and each side panel.

FIG. 7. Flat-folding box cover form with four side panels and a top panel with aperture with bendable hinges between the top and side panels. The flat-folding box cover form has flaps on one edge of each side panel.

FIG. 8. Flat-folding box cover form with four side panels and a top panel with aperture with a decorative layer is attached.

FIG. 9. Decorative flat-folding box cover layer with four side panels and a top panel with aperture that can be attached to a flat-folding box cover form. The decorative layer may be paper, cardstock, fabric or other material.

FIG. 10. Decorative flat-folding box cover layer attached to the flat-folding box cover form.

FIG. 11. Assembled flat-folding structural frame for a box cover with individual decorations on each side of the structural frame.

FIG. 12 Tissue box cover assembled with individual decorations or pictures on each side of the box.

FIG. 13. Flat-folding box cover form with four side panels and a top panel with aperture, with one flap on each side panel. Pairs of snaps with corresponding mates on the flap and the adjacent side panel act as the closure mechanism.

FIG. 14. Flat-folding box cover form with four side panels and a top panel with aperture with one flap on each side panel. An adhesive strip on the flap acts as the closure mechanism.

FIG. 15. Assembled flat-folding box cover form with four side panels and a top panel with aperture with clear tape or labels acting as the closure mechanism.

FIG. 16. Tray or base to hold the assembled flat-folding box cover.

DETAILED DESCRIPTION

One Piece Basic Design

FIG. 1 is an assembled box cover which is made by folding a decorative flat-folding box cover form FIG. 2 into a box cover. FIG. 2 is a decorative flat-folding box cover form with either standard or custom images or embellishments. It may be comprised of a single layer or several layers and coatings, but they are joined either permanently or temporarily and so are considered to be one integrated piece.

Two Piece Basic Design

FIG. 3 is a flat-folding clear plastic box cover form that fits over a decorative flat-folding box cover form FIG. 2. The flat-folding clear plastic box cover form FIG. 3 and the decorative flat-folding box cover form FIG. 2 are not permanently joined and so are considered to be two separate pieces. The flat-folding clear plastic box cover from FIG. 3 may be removed.

One-Piece Design Variations—Layout

FIG. 4 is the basic flat-folding box cover form with flaps on one edge of the side panels and FIG. 5 is the basic flat-folding box cover form with flaps on both edges of the side panels. The flaps are used to hold closure mechanisms, such as magnets or hook and loop fastners and also to create a finished look along the seams.

One-Piece Design Variations—Folding Mechanism

FIG. 6 is a flat-folding box cover from with bendable hinges connecting the top panel and the side panels. The bendable hinges facilitate the box cover retaining its shape when assembled.

FIG. 7 is a flat-folding box cover form with bendable hinges and side flaps.

One-Piece Design Variations—Wrapped

FIG. 8 is a flat-folding box cover with four side panels and a top panel with aperture with a decorative layer is attached. FIG. 9 is a decorative flat-folding box cover layer with four side panels and a top panel with aperture that can be attached to a flat-folding box cover form. The decorative layer may be paper, cardstock, fabric or other material. FIG. 10 is a decorative flat-folding box cover layer attached to the flat-folding box cover. The decorative layer may be fabric or paper or other material and may be either permanently affixed to the base form or it may be removable.

Two-Piece Design Variations—Layout

FIG. 11 is an assembled flat-folding structural frame for a box cover with individual decorations on each side of the structural frame. FIG. 12 is a tissue box cover assembled with individual decorations or pictures on each side of the box.

Closure Mechanism Variations

FIG. 13 shows the flat-folding box cover form with flaps on one edge of the side panels with pairs of snaps on the flaps and the adjacent side panels. FIG. 14 shows how the flat-folding box cover form with flaps on one edge can be assembled by putting adhesive on the flaps. FIG. 15 shows an assembled box cover with clear tape on the outside of the box cover holding it together. Other closure mechanisms may be employed and include, but are not limited to: snaps, magnets, tape, adhesives, glue dots, adhesive strips and labels, hook & loop, button & string, button & hook, snap-fit joints etc. Closures may be on either the inside or the outside of the box or neither or both. Closures may be on either the decorative layer or the clear plastic layer or neither or both.

Additional Options

A tray or base FIG. 16 may have slots to hold the side panels of the box cover in place. Any of the design variations may use a tray or base.

Additional Options for Customizing the Box, Both for Other Applications and to Allow End-Users to Use their Own Images.

Note: These options are not shown in the drawings.

The box cover can be configured to cover all standard tissue box sizes and configured to go into other box shapes. Box covers can be configured to fit over dispensers for paper hand towels, moist hand wipes, cosmetic wipes, baby wipes etc.

In additional embodiments, the decorative designs might be furnished by the end user either to the manufacturer or the selling entity for use as decoration for either or both top panels and side panels.

In additional embodiments, the end user may select to customize some aspects of the configuration by choosing from a set of design options provided by a seller.

In additional embodiments the plastic overlay might have slots where photos or other items could be inserted by the eventual purchaser.

In some additional embodiments the flat-folding box cover will be produced in a kit format. Some of the potential kit embodiments are:

a. The kit may be an undecorated flat-folding box cover. The consumer would supply the embellishments.

b. The kit may be a partial set of components. The consumer may need to purchase additional items in order to complete a flat-folding box cover.

c. The kit may be all inclusive with everything needed to make a flat-folding box cover and may include, but is not limited to: decorative layers, lining layers, coating/protective layers, panels, stiffeners, fasteners, decorative ring, adhesives, and embellishments. The kit may contain the actual components or the patterns from which components may be created.

d. The kit may include software to create embellishments.

e. The kit may specify links to websites where embellishments may be created, purchased or downloaded. 

We claim:
 1. A flat-folding box cover for tissues and other items that provides decorative options comprising: a. a flat-sheet cardstock cutout with a top panel and four side panels of proper dimensions and of the proper location for a desired size folded box cover with an aperture in the middle of the top panel; b. the side panels on the cardstock cutout each having magnets on one edge that will be aligned with magnets of the opposite polarity on flaps of the adjacent side pieces when the box is in the assembled configuration; c. the top panel to have an aperture cutout; d. the outer surfaces of the top panel and four side panels will have decorative images.
 2. The device of claim 1 wherein a the cutout is five piece flat-sheet card stock cutout with the top panel aperture the middle piece, and four side panels extending, one each, from the four edges of the top panel;
 3. The device of claim 1 wherein said cutout has scored line between the edges of top panel and side panels;
 4. The device of claim 1 with stiffening pieces attached to the side and top panels;
 5. The device of claim 1 wherein magnets are position one edge of the side panels, and the flaps on the edge of the side panels are folded over the magnets and fastened to side panels;
 6. The device of claim 1 wherein the flap on the other side of each side panel from the edge with magnets have magnets positioned on them to align with the magnets on the edge of adjacent side panels;
 7. The device of claim 1 wherein an inner lining of material is fastened to interior surface of the cardstock cutout, covering the top panel, side panels and flaps with magnets;
 8. The device of claim 1 wherein the decorative image is covered with a coating or a transparent plastic laminate sheet
 9. The device of claim 1 wherein an ornamental oval metal or plastic reinforcing ring, the same dimensions as the aperture in the top panel in the cardboard cutoff, is placed in the aperture opening.
 10. The device of claim 1 wherein a transparent laminate sheet is placed over the decorative images.
 11. The device of claim 1 where a coating is placed over the decorative images.
 12. The device of claim 1 where lamination sheets are applied by the retail purchaser or retail seller after applying their images of their choosing as the decorative image.
 13. A method of constructing a finished box from cardstock cutoff comprised of: a. magnets of one polarity are placed onto side panels b. magnets of the other polarity are placed on to side flaps c. the flaps holding magnets on the side panels are turned 90 degree inward; d. the side panels of the cardstock cutoff are folded downward, with the decorative side out, into a box shape; e. the magnets of opposite polarity on the side flaps are aligned with the magnets of one polarity on the edge of the side panels to create a finished box cover. 